Glass/carbon fiber reinforced plastic (GFRP/CFRP) and hybrid components have attracted increasing attention in lightweight applications. However, residual stresses induced in the manufacturing process of these components can result in warpage and, ev...
A geometrical modification on silicon wafers before the bonding process, aimed to decrease (1) the residual stress caused by glass frit bonding, is proposed. Finite element modeling showed that (2) by introducing this modification, the wafer out-of-p...
Additive manufacturing (AM), commonly known as 3D printing, has gained significant popularity for its ability to produce intricate parts with high precision. However, the presence of residual stresses and warpage deformation are common issues affecti...
Semi-crystalline polymers develop higher amounts of residual stress and part distortion (warpage) compared to amorphous polymers due to their crystalline nature. Additionally, the FDM processing parameters such as ambient temperature play an importan...
In fused deposition modelling (FDM) based on the selected raster pattern, the developed internal thermal residual stresses can vary considerably affecting the mechanical properties and leading to distinct part distortions. This phenomenon is more pro...
Analyses in the present work focus on understanding the influence of the WAAM (wire arc additive manufacturing) deposition pattern and travel speed on residual stress and warpage in aluminum alloy. The thermal profiles are analyzed using thermomechan...
Microinjection molding technology for degradable polymer stents has good development potential. However, there is a very complicated relationship between molding quality and process parameters of microinjection, and it is hard to determine the best c...
This study presents an experimental and numerical investigation of warpage in injection-moulded ABS plates, with emphasis on the influence of modelling assumptions and residual stress development on warpage prediction. Two sets of processing conditio...
Material extrusion additive manufacturing, commonly implemented as fused deposition modeling (FDM) or fused filament fabrication (FFF), has evolved into a manufacturing route for reinforced thermoplastic composites, including particle-filled, short-f...
Part warpage and residual stress are two of the main challenges for metal additive manufacturing (AM) as they result in lower geometric precision and poor mechanical properties of the products. This work investigates the effect of the building strate...
While material extrusion via fused filament fabrication (FFF) offers design flexibility and rapid prototyping, its practical use in engineering is limited by mechanical challenges, including residual stresses, geometric distortions, and potential int...
The current work investigates the auxetic tensile deformation behavior of the inversehoneycomb structure with 5 × 5 cells made of biodegradable poly(butylene adipate-coterephthalate) (PBAT). Fused deposition modeling, an additive manufacturing...
A thermo-mechanical wafer-to-wafer bonding process is studied through experiments on the glass frit material and thermo-mechanical numerical simulations to evaluate the effect of the residual stresses on the wafer warpage. To experimentally character...
Accurate prediction of thermo-mechanical behavior in Fused Deposition Modeling (FDM) is often limited by mismatches between idealized Computer-Aided Design (CAD) geometry and path-dependent material deposition. This paper presents a G-code-driven, fi...
Nowadays, Fused Filament Fabrication (FFF) 3D printing offers promising opportunities for the customized manufacturing of ankle–foot orthoses (AFOs) targeted towards rehabilitation purposes. Polypropylene (PP) represents an ideal candidate in o...
A newly developed hot embossing technique which uses the localized rapid heating of a thin carbide-bonded graphene (CBG) coating, greatly reduces the energy consumption and promotes the fabrication efficiency. However, because of the non-isothermal h...
Given the growing global demand for high-performance microcomponents, while keeping the size of the microcomponents as small as possible, several manufacturers have chosen to increase the number of thin layers to increase the integration density. The...
This study examines simulative experimental investigations on the additive manufacturing of complex component geometries using 3D plasma metal deposition (3DPMD). Here, complex contour surfaces for a cross-rolling tool were produced from weld metals...
The material extrusion additive manufacturing (MEAM) process for polymers seems straightforward. However, several controlled and uncontrolled factors affect the 3D printed product quality, e.g., MEAM process parameters, thermomechanical properties of...
Chip bonding, an essential process in power semiconductor device packaging, commonly includes welding and nano-silver sintering. Currently, most of the research on chip bonding technology focuses on the thermal stress analysis of tin–lead solde...
To analyze the effects of nonlinear behavior characteristics of prepreg (PPG) among the insulating materials of substrate and the residual stress of laminating process on the warpage of substrate, this study investigated the continuous laminating pro...
Large glass fiber-reinforced polypropylene (GF-PP) shells are widely used in HVAC and automotive industries, but their injection molding suffers from severe warpage deformation, residual stress concentration, and inaccurate mechanical performance pre...
Additively manufactured thin-walled structures through selective laser melting (SLM) are of great interest in achieving carbon-neutral industrial manufacturing. However, residual stresses and warpages as well as recoater crashes often occur in SLM, l...
This paper presents a warpage analysis method that predicts the warpage behavior of electroplated Cu films on glass fiber-reinforced polymer (GFRP) packaging substrates. The analysis method is performed using the following sequence: fabricate specime...
Fused filament fabrication (FFF) is a 3D printing technology that has been successfully demonstrated aboard the International Space Station (ISS), proving its suitability for space applications. In this study, we aimed to apply FFF to the 3D printing...
Axial cracking and circumferential wrinkling are found at the end of seamless steel tubes during multi-pass large deformations pushing diameter-reducing (PDR), which seriously affects product quality. However, the cracking and wrinkling mechanism of...
Warpage is one of the prominent issues in Fused Filament Fabrication. The cause of this is the rapid cooling of the polymer during extrusion. The residual thermal stresses accumulated within the print part result in a shape distortion and subsequent...
Injection molding is a high-volume manufacturing process widely used for producing polymer components; however, its process parameters strongly influence residual stress, warpage, and the resulting mechanical performance. This work presents a compreh...
Thin-walled structures are of great interest because of their use as lightweight components in aeronautical and aerospace engineering. The fabrication of these components by additive manufacturing (AM) often produces undesired warpage because of the...
Many challenges are associated with the injection compression molding process for producing a half-pallet (1320 mm × 1110 mm × 75 mm, length × width × height), which is butt-welded to another one for enhancing its strength. Th...
Eliminating warpage in injection molded polymeric parts is one of the most important problems in the injection molding industry today. This situation is critical in geometries that are particularly susceptible to warping due to their geometric featur...
For automotive GFRP structural components, beyond structural design, the warpage, residual stress/strain, and fiber orientation inevitably induced during the injection molding process significantly compromise their service performance. These factors...
Wire arc additive manufacturing (WAAM) is a metal additive manufacturing (AM) technique that has a high throughput and has seen a potential interest for replacing currently available subtractive manufacturing techniques. Contrary to other metal AM ma...
Residual stresses generated during laser powder bed fusion (LPBF) can cause substantial distortion in slender structures, compromising dimensional accuracy and structural reliability. This study tests the hypothesis that, under identical nominal proc...
The effects such as warpage, dimensional instability and environmental stress corrosion, due to the presence of residual stresses in polymeric products, are strongly dependent on injection molding conditions. The holding time and holding pressure bel...
Amorphous thermoplastics, as a type of engineering plastic material, are used in various industrial sectors. In order to manufacture high-performance products, it is important to optimize their forming process to mitigate residual stresses. However,...
Wire and arc additive manufacturing of stiffened ribs for fabricating large integral panel components holds promise for lightweight construction, but stress and warpage remain intractable problems. This work take stress in central lines as a research...
In this research, the thermal and structural responses of high-performance dielectric strength polymers in the injection molding process for multi-pin electrical connectors were thoroughly studied using Moldflow simulations and optimized via a Box&nd...
In this study, we developed a finite element model to assess the residual stress in the soldering and lamination processes during the fabrication of crystalline silicon (Si) photovoltaic (PV) modules. We found that Si wafers experience maximum thermo...
The process of curing of large thick composite parts needs attention regarding the formation of residual stresses. Similarly, novel reactive thermoplastics need investigating to produce an efficient thermal cure profile that decreases the risk of war...
Due to its high production rates and low cost as compared to other metal additive manufacturing processes, wire arc additive manufacturing (WAAM) has become an emerging technology in the manufacturing industry. However, the residual stress generation...
Mechanical responses after the uniaxial deformation of graded styrene–butadiene rubber (SBR) with a gradient in the crosslink points in the thickness direction were investigated as compared with those of homogenously vulcanized SBR samples. The...
Wire Arc Additive Manufacturing (WAAM), a specific type of Directed Energy Deposition (DED) additive manufacturing, has recently gained widespread attention for manufacturing industrial components. WAAM has many advantages compared to other metal AM...
The hybrid wafer bonding technique is drawing much interest in relation to three-dimensional integration technology, and its areas of application are expanding from image sensors to semiconductor memory packages. In hybrid bonding, the bond strength...
The food industry holds immense promise for 3D printing technology. Current research focuses mainly on optimizing food material composition, molding characteristics, and printing parameters. However, there is a notable lack of comprehensive studies o...
This study addresses a ubiquitous challenge in powder metallurgy: sintering distortion. Sintering distortion can have various causes. On one hand, external factors such as friction with the sintering support during sintering or temperature gradients...
Advanced composite materials have been widely applied in aerospace structures owing to their low weight, high strength, excellent fatigue resistance, and corrosion resistance. However, during the curing and molding processes of carbon-fiber composite...
Fibre deformation (or shearing of yarns) can develop during the liquid moulding of composites due to injection pressures or polymerisation (cross-linking) reactions (e.g., chemical shrinkage). On that premise, this may also induce potential residual...
The additive manufacturing process Selective Laser Melting (SLM) can generate large thermal gradients during the processing of metallic powder; this can in turn lead to increased residual stress formation within a component. Metal anchors or support...
Warping and dross formation are the main defects of an overhang structure formed by laser powder bed fusion. In order to study these defects, a seven−shaped overhang structure with different lengths and heights of the overhang was printed. The...
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